RESUMO Neste trabalho foi avaliada a influência do raio da ferramenta, do incremento vertical e da velocidade de avanço na estampagem incremental de alumínio AA1100-H14 com espessura inicial 0,5 mm. Foram realizados dezoito experimentos para conformação de formatos de hiperboloide até que ocorresse a fratura do material. Todos experimentos foram realizados por meio de um braço robótico, que conduziu a ferramenta por uma trajetória pré-determinada. Após a realização dos experimentos foram gerados gráficos de superfície de resposta e foi conduzida análise de regressão múltipla, a fim de determinar uma equação para estimar a máxima deformação no processo em função dos parâmetros selecionados. Foi verificado que a maior estampabilidade no processo é obtida pela associação dos menores valores do raio da ferramenta, do incremento vertical e da velocidade de avanço. Sendo que o raio da ferramenta foi o parâmetro que apresentou maior influência na estampabilidade.

ABSTRACT In this work it was evaluated the influence of the tool radius, step-down and feed rate in the incremental sheet forming of aluminum AA1100-H14 with initial thickness 0.5 mm. Eighteen experiments were performed to form hyperboloid shapes until the material fractured. All experiments were performed using a robotic arm, which guided the tool along a predetermined path. After conducting the experiments, response surface graphics were generated and multiple regression analysis was conducted in order to determine an equation to estimate the maximum strain in the process as a function of the selected parameters. It was found that the highest formability in the process is obtained by the association of the lowest values of the tool radius, step-down and feed rate. The tool radius was the parameter that had the greatest influence on the formability.

Knowing the importance of predicting acting forces during the formation process, our research has conducted 27 Single Point Incremental Forming (SPIF) experiments in hyperboloid format, followed by Finite Element Method (FEM) simulations and regression equations were determined to estimate the maximum axial force in the process. ANOVA analysis of variance was used to determine the significance of material parameters in the maximum axial force response. A multiple linear regression model was constructed to estimate the maximum axial force in the SPIF process. After the experiments, we were able to identify that the maximum axial force increases according to an increase in tool radius, sheet initial thickness, and strength coefficient values, as well as according to the decrease in the strain-hardening exponent. The FEM simulations are in agreement with the experimental values found, and the linear regression model has proven to be efficient to describe results, with R2 of 98.85% and a maximum percentage error of 11.5%.